Footwear construction

ABSTRACT

A sole assembly is provided including multiple compression units entrapped in a midsole and adjacent an outsole to efficiently distribute forces and to assist in correct foot motion during a gait cycle. The multiple compression units can be linked to one another to assist the foot in moving through an appropriate foot motion during a gait cycle. A heel compression unit can be linked to an arch compression unit, which can be linked to one or more forefoot compression units, which can be linked to a toe compression unit. The linking of the heel compression unit, the arch compression unit, and the forefoot compression unit to one another can resist torsional movement of the units between one another, thereby providing a more stable foot support, while still providing impact-attenuation and force distribution through the sole assembly.

BACKGROUND OF THE INVENTION

The present invention relates to footwear, and more particularly to asole assembly for footwear.

There are a variety of footwear constructed for efficient function indifferent activities. Many footwear are designed to provide a high levelof stable support, coupled with impact attenuation upon engagement withan underfoot surface, such as the ground. Much of the support and impactprotection afforded by footwear is attributable to the configuration ofthe sole. The sole protects the foot by dispersing significant forcescaused by running, jumping, training and even walking. The sole alsoprovides cushioning that absorbs impact and protects the wearer'sappendages, such as their feet, ankles and knees, from the stressassociated with strenuous and even day-to-day activities. At the sametime, the sole plays a role in helping support the foot in its propershape to prevent a wearer's feet and legs from becoming fatigued overtime.

The objectives of providing adequate impact attenuation and providingsupport often compete with one another. A highly cushioned sole,designed to compress and efficiently absorb significant impact forces,may not provide sufficient foot support, and this may lead to prematurefoot fatigue. Such a cushioned sole also might not allow a properdistribution of forces along the bottom of the foot during a gait cycle,which can lead to an erratic torsional, lateral, or lengthwise twistingor rotation of the foot, which can be deleterious to the gait of thewearer. On the other hand, an overly firm sole, designed to providesupport and stabilize the foot during the gait cycle, may feeluncomfortable, and may not provide the cushioning needed to protect thewearer against potential damage or injury associated with repeatedground impact. Furthermore, such a sole might be so rigid that itimpairs the foot from following its natural flexing and bending formthrough the gait cycle, which can also alter the wearer's gait in such away so as to reduce efficiency and energy return.

Accordingly, there is a reason for improving developing footwear soleconstructions that provide an appropriate balance between impactattenuation, durability, and support.

SUMMARY OF THE INVENTION

A sole assembly is provided including multiple compression unitsentrapped in a midsole and adjacent an outsole to efficiently distributeforces and to assist in correct foot motion during a gait cycle.

In one embodiment, multiple compression units are linked to one anotherto assist the foot in moving through an appropriate foot motion during agait cycle. For example, a heel compression unit can be linked to anarch compression unit, which can be linked to one or more forefootcompression units, which can be linked to a toe compression unit. Thelinking of the heel compression unit, the arch compression unit and theforefoot compression unit to one another can resist torsional movementof the units relative to one another, thereby providing a more stablefoot support.

In a further embodiment, the heel compression unit, the arch compressionunit and the forefoot compression unit can form an integral single piececompression unit body. A main body of the midsole, which may be referredto as a midsole body, can be molded around the compression unit body,with the single piece unit entrapped in the main body. The main body andthe single piece unit can function like an integral midsole, whileproviding the cushioning of the compression units and the structure ofthe main body for underfoot support and for controlling the compressionof the compression units.

In another embodiment, the heel compression unit can be disposed under acalcaneus bone of a wearer, the arch compression unit can be disposedunder the cuneiforms, the one or more forefoot compression units can bedisposed under the heads of metatarsals, and the toe compression unitcan be disposed under the toe bones of the wearer.

In still another embodiment, the main body can be constructed from afirst material having a first durometer, and the compression unit bodycan be constructed from the first material or a different material, andcan have a second durometer. The first durometer can be at least 10durometer points on the Asker C scale greater than the second durometerso that the compression units can compress more and can rebound quickerthan the main body of the midsole. Optionally, the first durometer canbe 55 Asker C, and the second durometer can be 45 Asker C.

In even another embodiment, the heel compression unit, the archcompression unit, and the first forefoot compression unit can each begenerally in the form of an ellipsoid. An upper surface of therespective ellipsoids, and optionally an upper half, can be entrapped inthe main body of the midsole. A lower surface of the respectiveellipsoids can form at least a portion of the respective heelcompression unit lower surface, the arch compression unit lower surface,and the first forefoot compression unit lower surface.

In yet another embodiment, the compression body can include a secondforefoot compression unit and the above noted toe compression unit.These additional units can be connected via additional connectorsextending between the units.

In a further embodiment, the respective connectors of the compressionunit body between compression units can extend upward from the lowersurface of the main body to form one or more ridges. These ridges, beingpart of the compression unit body, can be bordered on opposing sides bythe lower surface of the main body. Optionally, the outsole includesrespective connector covers that conceal the first respective ridgesthereunder, but not the lower surface of the main body on opposing sidesof the ridges.

In still a further embodiment, each of the respective compression unitscan include a compression unit lug. The compression unit lug can begenerally centrally located on each respective unit. The compressionunit lug can extend from a lower surface of the compression unit apredefined height.

In still yet a further embodiment, the outsole can define a plurality ofapertures, for example, in the heel, arch, forefoot and toe regions ofthe footwear. These apertures can be sized and shaped so that thecompression unit lugs in those areas can extend at least partiallythrough the respective apertures. In some cases, the predefined heightis greater than a thickness of the outsole in the region around theaperture. In this manner, the lug extends below the outsole groundcontacting surface so that the lug can optionally engage the groundbefore the outsole in that area, providing compression and impactattenuation.

In even a further embodiment, the compression units and the lugs thereofcan be disposed under certain bones of the foot to specificallyattenuate impact and provide energy return at certain parts of thewearer's gait.

The current embodiments of the footwear herein provide benefits inimpact attenuation, foot motion, and energy return that previously havebeen unachievable. For example, the compression unit body can interactwith the main body of the midsole to compress and thereby cushion thefoot during different stages of a gait cycle. The linking of thecompression units also stabilizes the foot, resisting torsional movementbetween units. The compression of the softer compression units in aharder midsole main body also assists in storing and returning theassociated energy through the compression units to provide a higherdegree of energy return.

These and other objects, advantages, and features of the invention willbe more fully understood and appreciated by reference to the descriptionof the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it isto be understood that the invention is not limited to the details ofoperation or to the details of construction and the arrangement of thecomponents set forth in the following description or illustrated in thedrawings. The invention may be implemented in various other embodimentsand of being practiced or being carried out in alternative ways notexpressly disclosed herein. Also, it is to be understood that thephraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting. The use of“including” and “comprising” and variations thereof is meant toencompass the items listed thereafter and equivalents thereof as well asadditional items and equivalents thereof. Further, enumeration may beused in the description of various embodiments. Unless otherwiseexpressly stated, the use of enumeration should not be construed aslimiting the invention to any specific order or number of components.Nor should the use of enumeration be construed as excluding from thescope of the invention any additional steps or components that might becombined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom plan view of a current embodiment of the footwear andthe sole assembly;

FIG. 2 is an exploded view of an outsole and a midsole of the soleassembly, the midsole including a midsole body and a compression unitbody;

FIG. 3 is a side view of the sole assembly;

FIG. 4 is a section view of the sole assembly taken along line IV-IV inFIG. 1;

FIG. 5 is a section view of the sole assembly taken along line V-V inFIG. 1;

FIG. 6 is a section view of the sole assembly taken along line VI-VI inFIG. 1; and

FIG. 7 is a top view of the sole assembly illustrating the embeddedcompression units in the midsole body.

DESCRIPTION OF THE CURRENT EMBODIMENTS

A current embodiment of the footwear is illustrated in FIGS. 1-7, andgenerally designated 10. In these embodiments, the improved article offootwear includes a sole assembly configured to provide benefits inimpact attenuation, foot motion, and energy return.

Although the current embodiment of footwear is illustrated in thecontext of a performance shoe, it may be incorporated into any type orstyle of footwear, including casual shoes, trail shoes and boots, hikingshoes, work boots, all-terrain shoes, barefoot running shoes, athleticshoes, running shoes, sneakers, conventional tennis shoes, walkingshoes, multisport footwear, boots, dress shoes or any other type offootwear or footwear components. It also should be noted thatdirectional terms, such as “vertical,” “horizontal,” “top,” “bottom,”“upper,” “lower,” “inner,” “inwardly,” “outer”, “outwardly,” “below” and“above” are used to assist in describing the embodiments based on theorientation of the embodiments shown in the illustrations.

Further, the terms “medial,” “lateral” and “longitudinal” are used inthe manner commonly used in connection with footwear. For example, whenused in referring to a side of the shoe, the term “medial” refers to theinward side (that is, the side facing the other shoe) and “lateral”refers to the outward side. When used in referring to a direction, theterm “longitudinal direction” refers to a direction generally extendingalong the length of the shoe between toe and heel, and the term “lateraldirection” refers to a direction generally extending across the width ofthe shoe between the medial and lateral sides of the shoe. The use ofdirectional terms should not be interpreted to limit the invention toany specific orientation.

Additionally, as used herein, the term “arch region” (or arch ormidfoot) refers generally to the portion of the footwear or soleassembly corresponding to the arch or midfoot of the wearer's foot; theterm “forefoot region” (or forefoot) refers generally to the portion ofthe footwear forward of the arch region corresponding to the forefoot(for example, including the ball and the toes) of a wearer's foot; andthe term “heel region” (or heel) refers generally to that portion of thefootwear rearward of the arch region corresponding to the heel of thewearer's foot. The forefoot region 22, arch region or midfoot region 24and heel region 26 generally are identified in FIG. 3. However, it is tobe understood that delineation of these regions may vary depending uponthe configuration of the sole assembly and/or footwear. Additionally,the sole assembly 14 defines a longitudinal axis LA, shown in FIG. 1,extending from the heel region 26 to the forefoot region 22.

The current embodiments of the footwear 10 can include features that arepositioned relative to certain bones in a foot of the wearer. Forexample, the metatarsals M extend generally in the forefoot region 22toward the toes T. The metatarsals M can extend into the midfoot region24, depending on the anatomy of the wearer. The cuneiform bones CBgenerally are disposed in the midfoot region 24 and form with themetatarsals M a portion of the instep I across the top of the wearer'sfoot. Rearward of the cuneiform bones CB is the talus TS which extendsabove the calcaneum or calcaneus bone C. Sometimes, the calcaneus bone Cis referred to herein as the heel bone or heel of the wearer's foot.

The footwear 10 can include a textile upper 12 (not shown in full, seeFIG. 4) and a sole assembly 14. The upper 12 can be formed from avariety of material elements joined together to cover at least a portionof the wearer's foot. The material elements can be selected based on theintended uses of the article of footwear 10, and can include synthetictextiles, mesh textiles, polymers or leather, for example. The upper 12is generally constructed to not impede the flexibility of the soleassembly 14, and can include stretchable or elastic material elements.For example, the material elements can include Lycra™, neoprene orspandex, and optionally can be knitted or weaved. The upper 12 caninclude one or more closure elements, including for example shoelaces orhook and loop fasteners. The upper 12 additionally includes an upperopening for receiving the wearer's foot and a lower periphery forattachment to the sole assembly 14.

As shown in FIGS. 1 and 2, the sole assembly 14 can include a midsole 18and an outsole 20, but more or fewer elements of the sole assembly 14can be included in other embodiments. For example, some embodiments caninclude a footbed, while other embodiments can include only the footbedand an outsole. The sole assembly 14 can include foam with a cushioningtop portion and a firmer, wear resistant bottom portion. The componentsof the sole assembly 14 may individually and/or collectively provide thearticle of footwear 10 with a number of attributes, such as support,rigidity, flexibility, stability, cushioning, comfort, reduced weight,and/or other attributes.

Referring in particular to FIG. 2, the midsole 18 includes a midsolebody 28 including a lower surface 30, and an upper surface 32. Themidsole 18 can be constructed from a material having a density that isgenerally less dense than the density of the outsole 20; for example,ethyl vinyl acetate (EVA), polyurethane (PU), latex, foam, a gel orother materials. Generally, the density of the midsole can be selectedso that it compresses relatively easily to provide cushion to thewearer's foot, for example, the heel. The midsole body 28 can beconstructed of a first material having a first durometer. As usedherein, “durometer” refers to any standard or other suitable durometermeasurement (e.g., Asker C or Shore A durometer hardness value) thatprovides an indication of hardness and/or flexibility of the material.Generally, lower durometer values indicates a softer/more flexiblematerial and higher durometer values indicate a harder/less flexiblematerial.

The midsole 18 includes a compression unit body 38 that defines multiplecompression units linked to one another via respective connectingmembers. The compression unit body 38 includes a heel compression unit40, an arch compression unit 60, and a first forefoot compression unit80. Referring to FIG. 7, the heel compression unit 40 is configured tobe positioned under a calcaneus bone C of a wearer, the arch compressionunit 60 is configured to be positioned under a cuneiform bone CB of thewearer, and the first forefoot compression 60 unit is configured to bepositioned under at least one metatarsal M head of the foot.

The heel compression unit 40 includes a heel compression unit lowersurface 42 having a heel compression unit lug 44 projecting from thelower surface 42. The heel compression unit 40 is linked via a firstconnector 46 to the arch compression unit 60. The arch compression unitincludes an arch compression unit lower surface 62 having an archcompression unit lug 64 projecting from the lower surface 62. The archcompression unit 60 is linked via a second connector 66 to the firstforefoot compression unit 80. The first forefoot compression unit 80includes a first forefoot compression unit lower surface 62 having afirst forefoot compression unit lug 84 projecting from the lower surface82. The lugs 44, 64, 84 are generally circular in cross section, thoughother shapes are contemplated herein, and can be generally centrallylocated on each respective compression unit 40, 60, 80. Each of the heelcompression unit 40, the arch compression unit 60, and the firstforefoot compression unit 80 can include an annular groove 50, 70, 90 ona lower surface of their respective lugs 44, 64, 84. The grooves 50, 70,90 increase the compressibility of the lugs 44, 64, 84, which canfurther diffuse the ground impact force and aid in the cushioningeffect. Further, the compression unit lugs 44, 64, 84 can extend fromthe lower surface 42, 62, 82 of the compression units 40, 60, 80 apredefined height. As a non-limiting example, the compression unit lugs44, 66, 84 can extend 0.5 mm from the lower surface 42, 62, 82,optionally about 0.5 mm to 1.0 mm, and even further optionally at least1.0 mm.

The heel compression unit 40, the first connector 46, the archcompression unit 60, the second connector 66, and the first forefootcompression unit 80 can be a unitary, integrally molded structureconstructed from the first material or a different material. Even whenconstructed from the first material, the compression unit body 38 canhave a second durometer which is less than the first durometer. Thefirst durometer can optionally be at least 10 durometer points on theAsker C scale greater than the second durometer, further optionallybetween 10 and 20 durometer points greater, and even further optionallyabout 20 durometer points greater. As a non-limiting example, themidsole body 28 can have a durometer of about 55 Asker C and the seconddurometer can be about 45 Asker C. The first durometer can be optionally45 to about 65 Asker C and the compression unit body 38 can have adurometer of optionally 35 to about 55 Asker C, or further optionally 25to about 35 Asker C. The midsole body 28 can be “harder” than thecompression unit body 38 so that the compression units 40, 60, 80provide zonal cushioning in the heel and/or on the ball of the foot asdiscussed in further detail below.

The heel compression unit 40, the arch compression unit 60, and thefirst forefoot compression unit 80 can each be generally ellipsoid inshape. It should be understood that the ellipsoid shape, as used herein,of the compression units can be, at least in part, flattened, partiallyplanar, broken, uneven, and/or interrupted, and should not be regardedas so limiting. The heel compression unit 40, the arch compression unit60, and the first forefoot compression unit 80 each include a respectiveupper surface 52, 72, 92 and a lower surface 42, 62, 82. The uppersurfaces 52, 72, 92 of the ellipsoids can be entrapped in the midsolebody 28 and disposed below the upper surface 32 of the midsole body 28,as illustrated in FIG. 4. Optionally, an upper half of the ellipsoid canbe entrapped in the midsole body 28. The lower surface of each of theellipsoids can form at least a portion of the lower surface 42, 62, 82of each of the respective compression units 40, 60, 80. It should beunderstood that the lower surfaces 42, 62, 82 can include the curved“sides” of the ellipsoid, and is not limited to the lowest extentsurface of the compression units 40, 60, 80.

The first connector 46 extends upward from the lower surface 42 of theheel compression unit 40 to form a first ridge bordered on opposingsides by the lower surface 30 of the midsole body 28. In a similarmanner, the second connector 66 extends upward from the lower surface 62of the arch compression unit 60 to form a second ridge bordered onopposing sides by the lower surface 30 of the midsole body 28.

Referring to FIGS. 4 and 5, the midsole body 28 defines a firstthickness between the first forefoot compression unit 80 upper portionor surface 92 and the upper surface 32 of the midsole body 28. The firstforefoot compression unit 80 defines a second thickness between thefirst forefoot compression unit 80 upper portion 92 and the lowersurface 82 of the first forefoot compression unit 80. The archcompression unit 60 defines a third thickness between the archcompression unit 60 upper portion 72 and the lower surface 62 of thearch compression unit 60. The ratio of the second thickness relative tothe first thickness can optionally be at least 1.1:1, further optionallybetween 1.3:1 and 1.8:1, and even further optionally about 1.8:1. Theratio of the first thickness relative to the third thickness can beoptionally at least 2:1, further optionally between 2.1:1 and 2.8:1, andeven further optionally about 2.8:1.

Referring back to FIG. 2, the sole assembly 14 includes the outsole 20which is joined with the midsole body 28 and the compression unit body38. The outsole 20 includes a substantially dome shaped heel cover 56that is disposed over and covers the heel compression unit 40 andincludes an outsole heel aperture 48 defined in and through the outsole20; a substantially dome shaped arch cover 76 that covers the archcompression unit 60 and includes an outsole arch aperture 68; and asubstantially dome shaped first forefoot cover 96 that covers the firstforefoot compression unit 80 and includes an outsole first forefootaperture 88. The covers are linked to one another. For example, the heelcover 56 is linked via a first connector cover 58 to the arch cover 76,and the arch cover 76 is linked via a second connector cover 78 to thefirst forefoot cover 96. Further, the outsole 20 has a lower surfacethat defines a ground contacting surface 140. The outsole 20 can besecured to the midsole 18 in any conventional manner, for example withadhesives, cement, injection molding, pour molding or any othertechnique used to join an outsole and a midsole.

The apertures 48, 68, 88 can be sized and shaped so that the compressionunit lugs 40, 60, 80 in those areas can extend at least partiallythrough the respective apertures. In some cases, the predefined heightis greater than a thickness of the outsole 20 in the region around theaperture 48, 68, 88. In this manner, the lug 44, 64, 84 extends belowthe ground contacting surface 140 of the outsole 20 so that the lug 44,64, 84 can optionally engage the ground before the outsole 20 in thatarea, providing compression and impact attenuation.

The outsole 20 can include multiple grooves and/or ridges arranged asdesired, and not necessarily in a repeating pattern. The grooves andridges can include one or more geometric shapes. The outsole 20 can beconstructed from a material suitable for providing a durable andnon-slip wear surface. For example, natural or synthetic rubber,thermoplastic polyurethane elastomers (TPU), nylon, polymer blends, wearresistant polymers, elastomers and/or other materials and combinationsthereof. The outsole material can have a relatively high durometer,greater than the first and second durometers of the midsole 18.

Referring to FIGS. 3-6, with the outsole 20 joined to the compressionunit body 28, the lugs are configured to align with and extendsubstantially through apertures in the outsole 20 to form the groundcontacting surface 140. The heel lug 44 extends through the outsole heelaperture 48, the arch lug 64 extends through the outsole arch aperture68, and the first forefoot lug 84 extends through the outsole firstforefoot aperture 88. The lugs 44, 64, 84 extend below the groundcontacting surface 140 of the outsole 20. The heel compression unitlower surface 42, the arch compression unit lower surface 62, and thefirst forefoot compression unit lower surface 82 each interrupt andextend below the lower surface 30 of the midsole body 28 when themidsole 18 and outsole 20 are in an unloaded state. It should beunderstood that the unloaded state refers to the footwear with no weightof the wearer applied. The loaded state is a result of the wearer'sweight and contact of the sole assembly 14 with a ground surface.

The lower surface 30 of the midsole body 28 intersects the firstforefoot compression unit 80 lower surface 82 at a boundary 142.Likewise, the lower surface 30 of the midsole body 28 intersects thelower surfaces 42, 62 of the heel compression unit 40 and the archcompression unit 60 at the boundary 142. The boundary 142 also extendsalong the intersection of the lower surface of the midsole body 28 andthe first and second connectors 46, 66 of the compression unit body 38.This boundary 142, on the lower surface 30 of the midsole body 28 aroundthe intersection of the midsole body 28 and the compression unit body38, however, is concealed by the outsole 20. Further, the firstconnector cover 58 of the outsole 20 conceals the first connector 46 ofthe compression unit body 38 thereunder, but not the lower surface 30 ofthe midsole body 28 on opposing sides thereof. The second connectorcover 78 of the outsole 20 conceals the second connector 66 of thecompression unit body 38 thereunder, but not the lower surface 30 of themidsole body 28 on opposing sides thereof. Accordingly, the boundary 142is concealed by the outsole 20, while the remainder of the lower surface30 of the midsole body 28 remains visible.

The footwear 10 provides benefits in impact attenuation, foot motion,and energy return that previously have been unachievable. For example,the compression unit body 38 can interact with the midsole body 28 tocompress and thereby cushion the foot during different stages of awearer's gait cycle. The linking of the compression units 40, 60, 80also stabilizes the foot, by resisting torsional movement between units.The linking of the heel compression unit 40, the arch compression unit60, and the forefoot compression unit 80 to one another can resisttorsional movement of the units between one another, thereby providing amore stable foot support. The compression of the softer compressionunits 40, 60, 80 in a harder midsole body 28 also assists in storing andreturning the associated energy through the compression units 40, 60, 80to provide a higher degree of energy return.

The compression units 40, 60, 80 and the lugs 44, 64, 84 thereof can bedisposed under certain bones of the foot to specifically attenuateimpact and provide energy return at certain parts of the wearer's gait.The compression units 40, 60, 80 are configured to aid in compression ofthe lugs 44, 64, 84 so that a bottom surface of each lug 44, 64, 84 isflush with the ground contacting surface 140 of the outsole 20 when themidsole 18 and the outsole 20 are in a loaded state. The impact forcecaused by the footwear impacting the ground is transferred to theoutsole 20 of the footwear. Because the lugs 44, 64, 84 extend below thelower surface of the outsole 20, part of the impact force is absorbed bythe lugs 44, 64, 84. Upon this transfer of the impact force to the lugs44, 64, 84 and the lower surface of the outsole 20, the force istransferred to and diffused by the compression units 40, 60, 80. Byvirtue of the mechanical interface between the compression units 40, 60,80 and the heel, arch, and first forefoot covers 56, 76, 96 of theoutsole 20, namely the thinning of the entrapped compression units 40,60, 80, a portion of the impact force is transferred from thecompression units 40, 60, 80 to the relatively harder midsole body 38.In effect, the resulting forces transferred to the heel, arch, and ballof the foot are only a portion of the initial impact forces, whichreduces the overall shock and impact to the foot of the wearer.

Additionally, the relative difference in durometer of the compressionunit body 38 and the midsole body 28 provide that the heel, arch, andfirst forefoot compression units 40, 60, 80 can rebound quicker than themidsole body 28. The effect of this is to provide increased energyreturn to the midsole 18 from the wearer's stride by reducing the amountof energy lost by the footwear. The lower durometer material used forthe compression unit body 38 deflects more than the material of themidsole body 28, compressing the compression unit body 38 between theharder outsole 20 and the relatively harder midsole body 28 to spreadout the impact force across the sole of the wearer's foot. When the soleassembly 14 is compressed between the foot and the ground surface, thecompression unit body 38 exerts an upward force on the lower surface 30of the midsole body 28, and, depending on the compressive force, candeflect and/or compress the midsole body 28. The compression unit body38, and perhaps the midsole body 28, deforms with each foot strike, andabsorbs and stores the kinetic energy produced when the foot hits theground. The midsole 18 then returns the stored energy to the wearer asthe foot leaves the ground. The lower durometer material used for thecompression unit body 38 stores the energy of that compression betterand returns to the original shape more quickly, providing a responsivefeel as it pushes back on the bottom of the wearer's foot during pushoff. The different in durometer of material for the midsole body 28 andcompression unit body 38 combine the softness of cushioned footwear withthe powerful, quick turnover of responsive footwear.

The sole assembly 14 also provides stability to the foot. The heelcompression unit lug 44, the arch compression unit lug 64, and the firstforefoot compression unit lug 84 each include a center, with each centeraligned along a common line CL, shown in FIG. 1. Additionally, asdescribed above, the compression units 40, 60, 80 include linking firstand second connectors 46, 66 therebetween to assist the foot in movingthrough an appropriate foot motion during a gait cycle. The linking ofthe heel compression unit 40, the arch compression unit 60, and theforefoot compression unit 80 to one another along that common line canhelp resist torsional movement of the units between one another, therebyproviding a more stable foot support. With this arrangement, the firstand second connectors 46, 66 provide support and stiffness along and/orgenerally parallel to the longitudinal axis LA of the footwear 10.

Optionally, the midsole 18 can include a second forefoot compressionunit 100. The second forefoot compression unit 100 includes a secondforefoot compression unit lower surface 102 with a second forefootcompression unit lug 104 projecting from the second lower surface 102.The second forefoot compression unit 100 can be linked via a thirdconnector 106 to the first forefoot compression unit 80. As describedabove, the lug 104 can extend through a second forefoot aperture 108defined by the outsole 20, extending below the ground contacting surface140 of the outsole 20. Similar to that described above, the lug 104 caninclude groove(s) 110 on the lower surface of the lug 104. Further, theoutsole 20 includes a substantially dome shaped second forefoot cover116 that covers the second forefoot compression unit 100, and is linkedto the first forefoot cover 96 via a second forefoot connector cover118.

In this exemplary arrangement, the first forefoot compression unit lug84 can be disposed on a lateral side of the longitudinal axis LA of thefootwear 10 and the second forefoot compression unit lug 104 can bedisposed on a medial side of a longitudinal axis LA of the footwear 10.The first forefoot compression unit 80 can be configured to bepositioned under at least one of the wearer's foot's fourth and fifthmetatarsal head, while the second forefoot compression unit 100 can beconfigured to be positioned under at least one of the first and secondmetatarsal heads. The second forefoot compression unit 100 can beconstructed from the first material or a different material, and canhave a second durometer.

Further optionally, the midsole 18 can include a toe compression unit120. The toe compression unit 120 can include a toe compression unitlower surface 122 with a toe compression unit lug 124 projecting fromthe lower surface 122. The toe compression unit 120 can be linked via afourth connector 126 to the second forefoot compression unit 100. Thelug 124 can extend through a toe aperture 128 defined by the outsole 20,extending below the ground contacting surface 140 of the outsole 20.Similar to that described above, the lug 124 can include groove(s) 100on the lower surface of the lug 124. Further, the outsole 20 can includea substantially dome shaped toe cover 136 that covers the toecompression unit 120, and may be linked to the second forefoot cover 116via a toe connector cover 138.

Manufacture of the footwear 10 will now be described. The upper 12 ismanufactured using generally conventional techniques and apparatus. Thebottom of a textile upper 12 can be closed by a Stroble or othersuitable construction.

The midsole body 28 can be formed by injection or pour molding the firstmaterial, with a first density, into a mold shaped to correspond to thefeatures of the midsole 18, including the upper and lower surfaces 32,30. The mold can optionally be contoured to include recessescomplementary to the compression unit body 38 formed in the desiredregions of the midsole body 28, and more specifically in the lowersurface 30 of the midsole body 28. As desired, other operations, such astrimming and drilling, can be performed on the midsole body 28 as well.

The compression unit body 38 can be formed by injection or pour moldingthe first material or a different material, with a second density, intoa mold shaped to correspond to the features of the compression unit body38, including the heel, arch, and first forefoot compression units 40,60, 80, the respective lugs 44, 64, 84 and their grooves 50, 70, 90, aswell as the second forefoot and toe compression units 100, 120, lugs104, 124, and grooves 110, 130 if included. The compression unit body 38can be molded with the midsole body 28. The compression unit body 38 canbe molded directly in the midsole body 28, or the midsole body 28 can bemolded around the compression unit body 38. Alternatively, thecompression unit body 38 and midsole body 28 can be co-molded in acommon mold. Insert molding and co-molding can form a unitary midsole18. Insert molding and co-molding can permanently couple the midsolebody 28 and the compression unit body 38. Co-molding can permanentlycouple the components, while at the same time molding the midsole body28 and compression unit body 38 into the desired shape. Furtheralternatively, the compression unit body 38 can be molded separately andadhered via any suitable means to the midsole body 28.

The outsole 20 can be injection molded or pour molded from a hard,durable material, such as rubber, using conventional molding apparatusand techniques. The pattern of grooves and/or ridges on the lowersurface of the outsole 20 and the outsole apertures 48, 68, 88, 108, 128defined by the outsole 20 can be formed during the molding operation.Optionally, these features, as well as any contours or shapes of theoutsole components, can be cut through or in the outsole 20 after theoutsole is formed. It is noted that the apertures 48, 68, 88, 108, 128can be molded or cut so that they align with the lugs 44, 64, 84, 104,124 of the compression units. The outsole 20 can be secured to themidsole 18 with cement, adhesive, or other attachment devices. Theoutsole components can be trimmed as desired to ensure a clean and flushfit with the upper and/or midsole as well.

The upper 20 can be joined with the midsole 18 and/or outsole 20. Thiscan be accomplished by adhering these components together or using anyother suitable means for affixing the components together.

Optionally, in the co-molding of the midsole body 28 and compressionunit body 38, the respective materials can engage and interface alongthe boundary 142, which is the interface between the lower surface 30 ofthe midsole body 28 and the lower surface of the compression unit 38.When molding the components, the two materials may bleed onto oneanother, creating a sloppy, uneven boundary line. This sloppyintersection is more obvious when the midsole body 28 and compressionunit body 38 are molded of different color material. The outsole 20 cancover and conceal this boundary 142, while the remainder of the lowersurface 30 of the midsole body 28 can remain visible.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,”“upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are usedto assist in describing the invention based on the orientation of theembodiments shown in the illustrations. The use of directional termsshould not be interpreted to limit the invention to any specificorientation(s).

The above description is that of current embodiments of the invention.Various alterations and changes can be made without departing from thespirit and broader aspects of the invention as defined in the appendedclaims, which are to be interpreted in accordance with the principles ofpatent law including the doctrine of equivalents. This disclosure ispresented for illustrative purposes and should not be interpreted as anexhaustive description of all embodiments of the invention or to limitthe scope of the claims to the specific elements illustrated ordescribed in connection with these embodiments. For example, and withoutlimitation, any individual element(s) of the described invention may bereplaced by alternative elements that provide substantially similarfunctionality or otherwise provide adequate operation. This includes,for example, presently known alternative elements, such as those thatmight be currently known to one skilled in the art, and alternativeelements that may be developed in the future, such as those that oneskilled in the art might, upon development, recognize as an alternative.Further, the disclosed embodiments include a plurality of features thatare described in concert and that might cooperatively provide acollection of benefits. The present invention is not limited to onlythose embodiments that include all of these features or that provide allof the stated benefits, except to the extent otherwise expressly setforth in the issued claims. Any reference to claim elements in thesingular, for example, using the articles “a,” “an,” “the” or “said,” isnot to be construed as limiting the element to the singular. Anyreference to claim elements as “at least one of X, Y and Z” is meant toinclude any one of X, Y or Z individually, and any combination of X, Yand Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

What is claimed is:
 1. A footwear comprising: an upper; a unitarymidsole joined with the upper, the midsole including a midsole bodyincluding an upper surface and a lower surface, the midsole body beingconstructed from a first material having a first durometer; a firstforefoot compression unit including a first forefoot compression unitlower surface and a first forefoot compression unit lug extending belowthe remainder of the first forefoot compression unit lower surface; asecond forefoot compression unit including a second forefoot compressionunit lower surface and a second forefoot compression unit lug projectingdownward and away from the second forefoot compression unit lowersurface distal from the first compression unit lug, the second forefootcompression unit and the first forefoot compression unit beingconstructed from the first material; and an outsole including an outsoleupper surface and an opposing ground contacting surface, the outsolejoined with the unitary midsole so that the first forefoot compressionunit lug extends through an outsole first forefoot aperture defined bythe outsole, the first forefoot compression unit lug extending adjacentthe ground contacting surface of the outsole, the second forefootcompression unit lug extending through an outsole second forefootaperture defined by the outsole, wherein the first forefoot compressionunit lower surface engages and is disposed above the outsole uppersurface, without extending beyond the ground contacting surface of theoutsole, while the first forefoot compression unit lug is free fromengagement with the outsole upper surface but extends through theoutsole first forefoot aperture, at least to the ground contactingsurface of the outsole.
 2. The footwear of claim 1, wherein the outsoleis constructed from a second material having a second durometer greaterthan the first durometer.
 3. The footwear of claim 1, wherein the firstforefoot compression unit lug extends beyond and lower than the groundcontacting surface of the outsole.
 4. The footwear of claim 1, whereinthe first forefoot compression unit lug originates adjacent the outsoleupper surface and terminates below the ground contacting surface of theoutsole.
 5. The footwear of claim 1, wherein the lower surface of themidsole borders the first forefoot compression unit at a boundary,wherein the boundary is concealed by the outsole.
 6. The footwear ofclaim 1, wherein the first forefoot compression unit lug is acylindrical projection that is surrounded by the outsole first forefootaperture.
 7. The footwear of claim 6, wherein the first forefootcompression unit lug includes a first portion that is below the outsoleground contacting surface and a second portion that is above the outsoleground contacting surface but below the outsole upper surface.
 8. Thefootwear of claim 1, wherein the first forefoot compression unit lugincludes a first predefined height, wherein the outsole includes anoutsole thickness in a region around the first forefoot aperture definedby the outsole, wherein the first predefined height is at least as greatas the outsole thickness.
 9. The footwear of claim 1, wherein the firstforefoot compression unit is configured to be positioned under at leastone of a fourth and fifth metatarsal head of a wearer, and the secondforefoot compression unit is configured to be positioned under at leastone of a first and second metatarsal head of the wearer.
 10. Thefootwear of claim 9, wherein the first forefoot compression unit lugincludes a first portion that is below the outsole ground contactingsurface and a second portion that is above the outsole ground contactingsurface.
 11. A footwear comprising: an upper; a midsole joined with theupper, the midsole including a midsole body including an upper surfaceand a lower surface, the midsole body constructed of a first materialhaving a first durometer; a compression unit body at least partiallydisposed in the lower surface, the compression unit body constructedfrom the first material but having a durometer that is less than thefirst durometer, the compression unit body including a first forefootcompression unit configured to be positioned under at least one of afourth and fifth metatarsal head of the wearer, the first forefootcompression unit distal from a second forefoot compression unitconfigured to be positioned under at least one of a first and a secondmetatarsal head of the wearer, the first forefoot compression unit andthe second forefoot compression unit forming an integral single pieceunit; and an outsole joined with the midsole body, the outsole includinga first cover that at least partially covers the first forefootcompression unit and a second cover that at least partially covers thesecond forefoot compression unit, wherein the first forefoot compressionunit includes a downward extending first forefoot compression unit lugincluding a first predefined height, wherein the outsole includes anoutsole thickness in a region around a first forefoot aperture definedby the outsole, wherein the first predefined height is at least as greatas the outsole thickness.
 12. The footwear of claim 11, wherein thefirst forefoot compression unit lug projects through the first forefootaperture in the outsole but the remainder of the first forefootcompression unit remains above the outsole,
 13. The footwear of claim11, wherein the first and second forefoot compression units originateadjacent an outsole upper surface and extend past an outsole groundcontacting surface.
 14. The footwear of claim 12, wherein the firstforefoot compression unit lug is disposed on a lateral side of alongitudinal axis of the footwear and the second forefoot compressionunit lug is disposed on a medial side of a longitudinal axis of thefootwear.
 15. The footwear of claim 11, wherein the first forefootcompression unit lug includes a first portion that is below the outsoleground contacting surface and a second portion that is above the outsoleground contacting surface but below the outsole upper surface.
 16. Thefootwear of claim 11, wherein the first forefoot compression unit lugincludes a first portion that is below the outsole ground contactingsurface and a second portion that is above the outsole ground contactingsurface.
 17. The footwear of claim 11, wherein the first forefootcompression unit lug is surrounded by an edge of an outsole firstaperture, wherein the first forefoot compression unit lug extends partlyabove and partly below the edge.